RAISING QUALITY STANDARDS BY SA-111

COST EFFECTIVE FILTRATION AND

SERFILCO
CARBON PURIFICATION OF PLATING SOLUTIONS

Metal finishing companies are well aware of the quality revolution that has been gathering momentum over recent years and whilst the
quality message, "right first time, every time" sounds simple, it requires much effort, dedication and commitment to achieve in practice.
Plating involves many critical process solutions that become contaminated with soluble and insoluble impurities which must be removed
to maintain acceptable quality standards for finished parts. This demand for efficient filtering equipment has been further stimulated by
advances in high throughput automatic plating machines and high speed processes where deterioration of plating quality can result
in substantial losses in production until the fault is resolved. In considering the role of depth cartridge filtration as a means to raising
quality standards cost effectively, this paper reviews the sources of contamination and the importance of flow, pressure and dirt holding
capacity when selecting cost effective equipment for filtration and carbon purification.

INTRODUCTION
Filtration of plating solutions is not a cure-all for all plating as a fume scrubber, absorbing fumes, oil mist vapors, sand
problems, but it remains a critical part of the whole effort to achieve blast dust and any other contaminant that gets past the intake
success. It is a part that cannot be overlooked or understated. A screen. (Some call it a filter, but in most cases, it is nothing
little filtration is better that no filtration, but a lot of filtration is often more than a coarse mesh such as you might find in a domes-
the only way to ensure the level of quality required on many plated tic heating system)
items. 3. Water can be a source of solids contamination. Whether it
Typically the benefits of an effective filtration system are: is city purified or recovered following waste treatment, the
● Faster Plating ● Better Throwing Power water will most certainly contain some particulate matter.
● More Agitation ● Less Roughness The plater has two options to counteract these sources of
● Less Brightener Consumption ● Less Porosity contamination. One is to remove the impurities after they get into
● Less Pitting ● Less Maintenance the plating tank. The other is to isolate as many of the solids and
● Less Staining ● Less Servicing other impurities as possible before they get to the electrolyte and
● Better Temperature Control ● Easier Carbon Purification disturb the plating process. Let us take a closer look at this second
option.
It is therefore somewhat surprising to find that platers treat
Filtration of cleaners can be important for several reasons. First,
filtration as a necessary evil and seldom give sufficient attention
it can add some life to the cleaner, which is a cost reduction ca-
to equipment selection. It often seems that initial flow rate and price
pable in most instances of paying for the equipment necessary to
are the only two factors considered when new equipment is
do the job. Second, it will reduce the possibility of solids and oils
purchased. As a direct consequence, it is not uncommon to find
from being carried down the line to the plating baths. This means
plating plants with inadequate filtration especially in terms of flow
that the plating filter will require less service and will be operating
and dirt holding capacity. Therefore, frequent servicing is neces-
at higher average flow rates. The best way to filter a cleaner is to
sary to maintain sufficient flow to prevent solid particles building
connect the pump to a floating skimmer and suction pipe assem-
up; rejects are therefore never far away. Only after a thorough
bly. The oily substances on the surface will be drawn to the skim-
understanding of the problems involved in achieving clarity and
mer while the heavier particles will be carried to the filter via solu-
purity of the plating solution can selection of the proper equipment
tion movement and be retained in the filter media. Carbon may be
be made.
used for additional absorption.
START THE CLEANING LINE
NOW TO THE PLATING TANK
These days, even statistical process control might be needed
Even if parts enter the plating tank completely clean and free
to meet quality requirements, however once the degree of quality
of solid contaminants, they will encounter other sources of con-
has been established, platers can proceed accordingly. Some
tamination, e.g.
platers tell us of their experiences which result in 5% rejects or more,
1. Random dirt - from ceilings, hoists, racks etc.
others as low as 1%. The plating may be the same, but if the speci-
2. Sludge - from unbagged anodes or from defective bags.
fications vary, the reject rate will follow accordingly. It all reverts to
3. Reaction products - precipitated in the plating bath - especially
cost and intention. What steps is the plater willing to take to achieve
iron hydroxide from nickel or zinc plating of steel parts.
the desired results?
The contamination from these sources, as well as drag-in of
Quality control people say you can't take shortcuts, never-
solids from prior steps, can produce a "dirt holding" that will require
theless all specifications have plus or minus tolerances which must
extreme vigilance to eradicate.
be carefully monitored and controlled. How can we apply this
From the plater's standpoint, this influx of solid contamination
approach to plating, and in particular, what does it have to do with
represents a serious threat to his chances of achieving "zero re-
cleaning? Remember, you can't expect to get good plating if the
jects". His only recourse is continuous filtration of the plating bath.
parts are not cleaned properly because dirty parts are bound to be
The question is: "How much filtration is enough to assure quality?"
carrying contaminants to the plating tank. Chemicals used in cleaning
dissolve, loosen and free impurities and contaminants from the sub- FLOW RATE AND VELOCITY
strate, but it is the rinsing which determines whether or not parts Flow rate is usually defined as "turnovers per hour". Figure 1
are actually clean when they enter the plating tank. shows the effect of turnovers per hour on solids removal and hence
OTHER SOURCES OF CONTAMINATION solution clarity. It can be seen that one turnover per hour is not very
effective in removing solids, achieving only 60% removal. Two
1. Fume extraction passes large quantities of air over the
turnovers will achieve around 84% removal, three achieve 92-94%
surface of process tanks. This air carries with it all sorts of
and four can reach 97-98%. For the ultimate in clarity, tanks should
contamination from other operations near and even far away
be turned over ten times per hour. Flow rate is the vehicle which
from the plating line. The electrolytes, aided by wetting agents,
provides the velocity or movement of solution which is necessary
pick up anything that drops in along the way.
to carry particulate matter to the filter. The higher the flow rate, the
2. Agitation with air creates a similar problem, the solution acts
greater the velocity, the better the filtration.

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RAISING QUALITY STANDARDS BY COST EFFECTIVE FILTRATION AND
CARBON PURIFICATION OF PLATING SOLUTIONS (cont'd).
Figure 1. Effect of flow rate on solids removal
Whilst this statement is unquestionably true, one should guard
against increasing flow rate without correspondingly increasing
the size of the filter chamber, otherwise the important balance
between flow rate and dirt holding capacity will be disturbed. The
ideal balance should not exceed 1000 liters/hr. per 10 in. cartridge,
otherwise pressure losses will increase, dirt holding capacity will
be reduced and the equipment will need to be serviced more
frequently.
WHY IS VELOCITY SO IMPORTANT?
1. Velocity enables fresh solution to be constantly brought back
to work, replacing depleted solution and carrying new metal
ions to be deposited; therefore velocity helps to increase the
speed of plating.
2. Velocity prevents temperature stratification (layers of hot or
cold solution).
3. Velocity can help prevent burning of the deposit in high cur-
rent density areas.
4. Velocity can help direct solution to specific areas such as
recesses or interior surfaces to achieve a more uniform
deposit.
5. Velocity created by a pump may also be used instead of air
agitation, eliminating the possibility of contaminants entering
the electrolyte for the air blower.
FILTER CARTRIDGES
Having emphasized the importance of flow rate and velocity
and recognizing that it is impractical to maintain a working solu-
tion totally free of particles, all steps must be taken to achieve the
degree of solution cleanliness necessary to reach the quality ob-
jective with "zero rejects"
What then are the best choices of filter cartridge and turnover
rate necessary to achieve the desired results?
1. Should the cartridge be very dense, stopping every possible
particle which could cause roughness by co-deposition, which
later could show up as rust or imperfection?
2. Should the cartridge be coarser, allowing higher flow rates to
achieve higher turnover rates?
Perhaps the best way to answer these questions is to pose
another, what is the size range of the particles and how many are
there?
If the answer is few and small, a very dense cartridge is rec-
ommended (0.1 to 5 micron). If large and many, a coarse cartridge
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SA-111
is best (10 to 100 micron), letting the solids form part of the filter-
ing process.
In either case, the cartridge must be able to hold the amount
of solids that enter the plating tank during the time between filter
servicing. Years ago "surface area" was the measurement used,
but it is more correct to refer to "dirt holding capacity".
For extremely critical applications requiring the utmost in clarity,
absolute submicron (0.1 or 0.2 micron) surface type cartridges might
be used. Therefore, if solid particles can be assumed to be at a
minimum, flow at a high turnover rate in excess of ten times per
hour could be maintained without flow reduction. If such cartridges
plug up too frequently, then a pre-filter consisting of coarser car-
tridges might be added.
For the majority of plating applications and yet where quality
is still very important, cartridges of 1 to 10 micron with a nominal
retention rating will provide excellent results; however, an impor-
tant question is can the solids be removed from the plating tank
before they are co-deposited onto the surface of the work? This is
again an example of the need for high flow rates which can be
maintained for extended periods by the use of coarser cartridges
and yet still achieve a high degree of solution clarity.
Oversizing the filter chamber adds additional dirt holding ca-
pacity, therefore when operating a filter with less flow per unit area,
the result is less pressure drop. This provides a more permeable
cake of contaminants thus allowing a bigger build-up of solids and
subsequent reduction of operating costs.
Wound cartridges make this possible because their construction
creates depth filtration (as opposed to surface filtration) as illus-
trated in Figure 2.
When a cartridge is manufactured, each layer is built-up from
the center core, becoming progressively more coarse because of
the increase in diameter. The micron rating is controlled by the dia-
mond pattern and the tension applied in the winding process. As
liquid passes through the cartridge, the larger particles are trapped
in the larger exterior diamond openings and progressively smaller
particles are trapped in the finer openings nearer the core.
It is a characteristic of wound cartridges that the coarser the
cartridge, the lower the cost, the greater the dirt holding capacity
and consequently the longer the ser-
vice life.
Whilst all cartridge filters have the
advantage of simplicity and conve-
nience in operation when compared
to disc filters, their greater dirt hold-
ing capacity with increased porosity
can be used to great advantage in
recirculatory filtration of plating solu-
tions.
Another advantage is that the dirt Figure 2
is held more tightly within the cartridge Depth wound
and recontamination due to failure or filter cartridges
bypass is much less likely. It is for this
reason that wound cartridges are often used in breweries for final
polishing after pre-coat filters.
SIZING THE FILTER CHAMBER
Technological developments are of little value unless the equip-
ment is properly applied. Of particular importance is sizing the fil-
ter chamber, otherwise insufficient dirt holding capacity will mean
frequent servicing to maintain a satisfactory flow rate. For most plating
baths, a good guide is to allow 1 x 10 in. cartridge per 200 liters of
solution but this figure should be adjusted depending on the par-
ticular application. For example, acid zinc or bright nickel plating
onto steel parts creates a much heavier "dirt" load than say acid
 SA-111

RAISING QUALITY STANDARDS BY COST EFFECTIVE FILTRATION AND

CARBON PURIFICATION OF PLATING SOLUTIONS (cont'd).

copper plating in a PCB plant. Both may demand a flow rate of Softening, carbon purification, reverse osmosis or ion exchange
3-4 turnovers per hour but filter chamber sizing would be quite dif- are not really filters in themselves, although they sometimes func-
ferent. Examples of solutions requiring higher flow rates with pro- tion as such. Each will operate to its maximum efficiency only if the
portionally smaller filter areas are electroforming and electroless water is filtered first, usually with 15 micron media, so as to be free
nickel plating baths where the dirt load is relatively light. Because of solids. Otherwise solids will coat over the resin in a softener or
dirt holding capacity is increased when the flow rate velocity through ion exchange bed and also over the carbon, or membrane in a
each cartridge is decreased, it therefore follows that: purification unit, preventing efficient adsorption. Trap filters of 1
— Time between servicing is increased or 3 micron are recommended to prevent migration of resin or car-
— Cartridge costs are reduced bon media.
— Labor costs are reduced The quality of water required will vary depending upon its ul-
— Solution loss is reduced timate use such as makeup water for an electroplating solution or
These benefits can be quantified as shown in Figure 3, from for rinsing. Solids entering the plating tank with the makeup water
which it can be seen that oversizing by a factor of 4 doubles the may amount to only 5% of the total to be filtered, but it is beneficial
dirt holding capacity per cartridge. Since the chamber holds 4 x to remove at source, because it is easier to replace filter media in
the number of cartridges, the filter is opened only 1/8 as often, re- the prefilter to a deionizer than it is to regenerate and wash the resin
ducing the labor by 87.5% for cartridge changing. bed. Filtration is especially important in the reverse osmosis pro-
cess, since solids will plug the pores in the membrane and decrease
Figure 3. Economics of filter chamber oversizing its efficiency.
Time Conserve water . . . save money
Number of Dirt Holding Between Cartridge Labor Cost/ Since the cost of water is continually rising, its efficient use is
Oversizing
Cartridges in Factors per Cartridge Consumption Solution Loss of increasing importance. This is also necessary in order to con-
Factor
Chamber* Cartridge Change Reduced by Reduced by serve limited water resources. Considerable reduction in rinse
1 C D T 0 0 water volume can be achieved with multiple counter flow rinse
2 2xC 1.5D 3T 34% 67% tanks, spray rinsing of parts and longer draining time of plating bar-
3 3xC 1.7D 5T 42% 80% rels. Conductivity meters can monitor and automatically control the
4 4xC 2.0D 8T 50% 87.5% dissolved solids concentration in a rinse tank by means of a signal
* Based on average sizing i.e. 1 x 10" (25cm) cartridge per 50 gallons (200L). to a solenoid valve on the water inlet. The reuse of water is also
feasible with an ion exchange or reverse osmosis treatment.
Figure 4 shows how in cartridge filter chambers the flow pat- Filtration of either in-line water supplies or recirculatory sys-
tern changes during the life cycle of a set of cartridges. In this ex- tems may be accomplished with depth-type cartridges, providing
ample the chamber contains 48 x 10 in. (or 24 x 20 in.) cartridges particle retention from 100 down to 1 micron or less if necessary
and the total flow remains constant at 20,000 lph until flow pattern with absolute ratings of 0.25 to 1 micron. The choice of filter is usually
B is reached. Only then does the total flow start to fall. dependent upon the amount of solids, the particle retention desired,
available space and initial investment consideration. Filter cham-
bers are available in both non-metallic and metallic construction.
Figure 4. Flow pattern through Pumps should provide adequate pressure to achieve the flow through
cartridge filter chamber the media on an economical basis before servicing of the filter is
required.
Flow Pattern 'B' Flow Pattern 'A' Improve quality . . . prevent rejects
Water filtration can prevent spotting of parts on final rinsing
10,000 LPH— 40" —2,000 LPH after anodizing or plating and prevent spray nozzles from plugging
up and causing a distorted spray. Even water used for flushing pump
5,000 LPH— 30" —3,000 LPH seals should be filtered to prevent gritty particles from causing
premature seal failure and leakage of the solution being pumped.
3,000 LPH— 20" —5,000 LPH
CARBON PURIFICATION
Most plating solutions contain organic additives such as bright-
2,000 LPH— 10" —10,000 LPH eners, stabilizers, levellers etc. During electrolysis some of these
20,000 LPH
chemicals are converted into undesirable organic compounds which
Total Flow In need to be completely removed or at least kept at a low level of
20,000 LPH concentration. Organic contamination can also be introduced from
Total Flow Out pretreatment chemicals, jigs, resists, etc. Depending on the solu-
tion, different methods of removal are employed.
Traditionally the whole bath is taken out of service and treated
FILTRATION OF WATER with powdered carbon at elevated temperature and then, after a
Clean water is an essential raw material for any plating or period of settlement, the solution is transferred to a separate tank.
anodizing process. Water from natural sources such as a well, This process is messy, time consuming and inevitably results in
lake, etc. probably needs softening for calcium removal or carbon some loss of solution. Nickel plating solutions are often continu-
treatment for the reduction of organic impurities. Certain ap- ously pumped over powdered carbon which has been precoated
plications require that the water be essentially free from all ions. onto the filters. Whilst this technique undoubtedly controls the level
This can be accomplished with an ion exchange and/or reverse of organic contamination it is in itself a messy, labor intensive pro-
osmosis treatment. cess requiring a certain degree of care on the part of the operator

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 SA-111

RAISING QUALITY STANDARDS BY COST EFFECTIVE FILTRATION AND

CARBON PURIFICATION OF PLATING SOLUTIONS (cont'd).

to ensure carbon does not enter the plating tank. The carbon is Regardless of which type of pump is used, there must be enough
normally replaced on a weekly basis although it is doubtful any pressure to maintain the desired flow rate even though the filter
useful purpose is served after the first few hours of circulation. cartridge becomes progressively clogged.
Unloading of the impurities back into solution can occur in some
instances. In-tank
An alternative technique now well accepted by many platers, Filter pump
utilizes granular carbon packed into a separate chamber connected chamber
Pump
to the downstream side of the filter pump system. A manually op-
erated control valve allows for bypass purification continuously or Filter
; ; ; chamber
intermittently as required (see Figure 5). The process is both ; ; ;
; ; ;
simple and effective, and because the filters are kept free of ;
;
;
;
;
;
; ; ;
carbon, they operate at higher flow rates for longer periods before ; ; ;
; ; ;
cleaning becomes necessary. ; ; ;
; ; ;
; ; ;
; ; ;
; ; ;
; ; ;
; ; ;
CARBON

FILTER Figure 7. Typical installation arrangements

CONTROL
VALVES PUMP
CONTROL
VALVES
Figure 5. Filter pump Figure 6. Carbon
with by-pass carbon purification chamber
purification chamber with trap filter
Pumps
All filtration systems depend on a pump to circulate the solu-
tion and almost all are manufactured from plastic materials. Most
are centrifugal, being either magnetic coupled without glands or
seals, or directly coupled incorporating either single or double me-
chanical seals with water flush.
Double seal pumps have advantages over single seal because
they eliminate the formation of salt crystals on the seal faces which
would otherwise cause leakage from abrasive wear. They may be
dry-run without damage and are particularly suitable for electro-
less nickel baths. For most solutions except electroless copper
and electroless nickel, magnetic coupled pumps to 30,000 lph
are generally preferred because of their simplicity, reliability and
leak free capability.
Alternatively for all solutions including chrome and electroless
processes, seal-less vertical pumps have distinct advantages to
offer the plater. For example, they will run dry indefinitely and there
are no seals to leak, neither are they unduly affected by the abra-
sive particles which are inevitably present in plating solutions. They
may be installed in or out of tank per the illustration in Figure 7.
Conclusion
Flow rate, pressure, filter cartridge porosity and size of filter
chamber all work together to affect solids retention by the filter in
a given period of time. The coarsest possible filter cartridge should
be selected to give the best clarity. If the filter does not provide the
clarity required, the plater may select a denser cartridge that loads
up faster but in the end removes less solids. At the other extreme,
it is possible to go to a coarse cartridge and not get any filtering at
all, even though the flow rate is very high. A judgement must be
made with all aspects of the application considered. The bottom
line is to achieve the highest solids removal because this maintains
the cleanest tank and gives the fewest rejects. When selecting a
filter system, don't forget the accessories. Valves may be added
to control or direct flow. Always include a pressure gauge to indi-
cate the condition of the filter, thereby ensuring that filters are ser-
viced at the optimum frequency.
To sum up, the essentials of an effective filtration system are:
● Adequate flow
● Adequate pressure
● Adequate flow to cartridge ratio
● Corrosion resistant
● Separate carbon purification chamber
● Adequate velocity
● Adequate dirt holding capacity
● Control valves and pressure gauge
● Reliable and economical
● Easy to service
Alan Chapman, SERFILCO Europe, Ltd
Reprinted from Product Finishing, March and April, 1992
Edited June, 1998

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